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EP1886749B1 - Outil de coupe pour usinage haute qualité et haut rendement et procédé de coupe l'utilisant - Google Patents

Outil de coupe pour usinage haute qualité et haut rendement et procédé de coupe l'utilisant Download PDF

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Publication number
EP1886749B1
EP1886749B1 EP06730386.7A EP06730386A EP1886749B1 EP 1886749 B1 EP1886749 B1 EP 1886749B1 EP 06730386 A EP06730386 A EP 06730386A EP 1886749 B1 EP1886749 B1 EP 1886749B1
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EP
European Patent Office
Prior art keywords
cutting
cutting edge
superfinishing
tool
finishing
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Application number
EP06730386.7A
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German (de)
English (en)
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EP1886749A4 (fr
EP1886749A1 (fr
Inventor
Yoshihiro Kuroda
Satoru Kukino
Katsumi Okamura
Tomohiro Fukaya
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Sumitomo Electric Hardmetal Corp
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Sumitomo Electric Hardmetal Corp
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Publication date
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Publication of EP1886749A1 publication Critical patent/EP1886749A1/fr
Publication of EP1886749A4 publication Critical patent/EP1886749A4/fr
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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23B—TURNING; BORING
    • B23B27/00—Tools for turning or boring machines; Tools of a similar kind in general; Accessories therefor
    • B23B27/14—Cutting tools of which the bits or tips or cutting inserts are of special material
    • B23B27/16—Cutting tools of which the bits or tips or cutting inserts are of special material with exchangeable cutting bits or cutting inserts, e.g. able to be clamped
    • B23B27/1614—Cutting tools of which the bits or tips or cutting inserts are of special material with exchangeable cutting bits or cutting inserts, e.g. able to be clamped with plate-like cutting inserts of special shape clamped against the walls of the recess in the shank by a clamping member acting upon the wall of a hole in the insert
    • B23B27/1622—Cutting tools of which the bits or tips or cutting inserts are of special material with exchangeable cutting bits or cutting inserts, e.g. able to be clamped with plate-like cutting inserts of special shape clamped against the walls of the recess in the shank by a clamping member acting upon the wall of a hole in the insert characterised by having a special shape
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23B—TURNING; BORING
    • B23B27/00—Tools for turning or boring machines; Tools of a similar kind in general; Accessories therefor
    • B23B27/14—Cutting tools of which the bits or tips or cutting inserts are of special material
    • B23B27/141—Specially shaped plate-like cutting inserts, i.e. length greater or equal to width, width greater than or equal to thickness
    • B23B27/145—Specially shaped plate-like cutting inserts, i.e. length greater or equal to width, width greater than or equal to thickness characterised by having a special shape
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23D—PLANING; SLOTTING; SHEARING; BROACHING; SAWING; FILING; SCRAPING; LIKE OPERATIONS FOR WORKING METAL BY REMOVING MATERIAL, NOT OTHERWISE PROVIDED FOR
    • B23D35/00—Tools for shearing machines or shearing devices; Holders or chucks for shearing tools
    • B23D35/002—Means for mounting the cutting members
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23B—TURNING; BORING
    • B23B2200/00—Details of cutting inserts
    • B23B2200/04—Overall shape
    • B23B2200/0428—Lozenge
    • B23B2200/0433—Lozenge rounded
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23B—TURNING; BORING
    • B23B2200/00—Details of cutting inserts
    • B23B2200/20—Top or side views of the cutting edge
    • B23B2200/201—Details of the nose radius and immediately surrounding area
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23B—TURNING; BORING
    • B23B2200/00—Details of cutting inserts
    • B23B2200/20—Top or side views of the cutting edge
    • B23B2200/204—Top or side views of the cutting edge with discontinuous cutting edge
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23B—TURNING; BORING
    • B23B2200/00—Details of cutting inserts
    • B23B2200/20—Top or side views of the cutting edge
    • B23B2200/208—Top or side views of the cutting edge with wiper, i.e. an auxiliary cutting edge to improve surface finish
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23B—TURNING; BORING
    • B23B2200/00—Details of cutting inserts
    • B23B2200/24—Cross section of the cutting edge
    • B23B2200/242—Cross section of the cutting edge bevelled or chamfered
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23B—TURNING; BORING
    • B23B2200/00—Details of cutting inserts
    • B23B2200/24—Cross section of the cutting edge
    • B23B2200/245—Cross section of the cutting edge rounded
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23B—TURNING; BORING
    • B23B2200/00—Details of cutting inserts
    • B23B2200/28—Angles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23B—TURNING; BORING
    • B23B2220/00—Details of turning, boring or drilling processes
    • B23B2220/24—Finishing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23B—TURNING; BORING
    • B23B2222/00—Materials of tools or workpieces composed of metals, alloys or metal matrices
    • B23B2222/04—Aluminium
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23B—TURNING; BORING
    • B23B2226/00—Materials of tools or workpieces not comprising a metal
    • B23B2226/12—Boron nitride
    • B23B2226/125—Boron nitride cubic [CBN]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23B—TURNING; BORING
    • B23B2226/00—Materials of tools or workpieces not comprising a metal
    • B23B2226/31—Diamond
    • B23B2226/315—Diamond polycrystalline [PCD]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23B—TURNING; BORING
    • B23B2240/00—Details of connections of tools or workpieces
    • B23B2240/08—Brazed connections
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23B—TURNING; BORING
    • B23B2270/00—Details of turning, boring or drilling machines, processes or tools not otherwise provided for
    • B23B2270/26—Burnishing
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T407/00—Cutters, for shaping
    • Y10T407/19—Rotary cutting tool
    • Y10T407/1952—Having peripherally spaced teeth
    • Y10T407/1962—Specified tooth shape or spacing
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T407/00—Cutters, for shaping
    • Y10T407/23—Cutters, for shaping including tool having plural alternatively usable cutting edges
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T407/00—Cutters, for shaping
    • Y10T407/27—Cutters, for shaping comprising tool of specific chemical composition
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T82/00—Turning
    • Y10T82/10—Process of turning
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T83/00—Cutting
    • Y10T83/04—Processes
    • Y10T83/0591—Cutting by direct application of fluent pressure to work

Definitions

  • This invention relates to a cutting tool capable of performing high-quality, high-efficiency cutting of workpieces according to the preamble of claim 1, and a method of cutting workpieces using such a cutting tool as defined in claim 8.
  • Cutting tools capable of performing high-quality, high-efficiency cutting of workpieces are disclosed in the below-mentioned Patent documents 1 and 2.
  • a prior art cutting tool according to the preamble of claim 1 is disclosed for example by EP 0 313 534 A2 .
  • the cutting tool disclosed in Patent document 1 is used for machining hardened steel and includes a major cutting edge which performs a major portion of the necessary cutting, and a minor cutting edge connecting with the major cutting edge to remove a affected layer formed on the surface of the workpiece by the major cutting edge and simultaneously finish the surface to required dimensions.
  • the cutting tool (indexable insert) disclosed in Patent document 2 includes a cutting edge for rough cutting and a cutting edge for finish cutting.
  • the cutting edge for finish cutting removes any feed mark formed on the surface of the workpiece when the cutting edge for rough cutting is fed to cut the workpiece.
  • Commercially available wiper inserts having wiper cutting edges also include a cutting edge for rough cutting and a cutting edge for finish cutting.
  • the minor cutting edge which defines an arcuate nose, removes a affected layer (also called "white etching layer") formed on the finished surface by the major cutting edge.
  • a affected layer also called "white etching layer”
  • the shape of the minor cutting edge tends to be transferred onto the finished surface in the form of corrugated feed marks, thus detrimentally influencing the surface roughness of the finished surface.
  • the surface roughness of the finished surface can be improved by reducing the depth of cut of the minor cutting edge and the feed rate of the tool, this solution will reduce the machining efficiency.
  • the finishing cutting edge of the cutting tool disclosed in Patent document 2 and the wiper cutting edge of a commercially available wiper insert are both basically used for cutting workpieces. These cutting edges cut portions that are left uncut by the cutting edge for rough cutting, i.e. the crests of the feed marks. Thus, the finishing cutting edge and the wiper cutting edge are not cut into the workpiece, exceeding the depth of cut d of the cutting edge for rough cutting, and therefore cannot remove any affected layer. They scarcely have the burnishing function, either. Thus, if residual compressive stress is required on the surface of the workpiece, it is necessary to burnish the surface of the workpiece, as with the tool of Patent document 1.
  • An object of the present invention is to achieve high-quality, high-efficiency machining of a workpiece such as hardened steel.
  • high-quality machining means to machine a workpiece such that a affected layer is formed on its finished surface in a reduced amount, its surface roughness is improved and compressive residual stress is applied thereto.
  • the cutting tool according to the invention as defined in claim 1 has hard members involved in cutting and having a finishing cutting edge which is first cut into a workpiece, and superfinishing cutting edges for burnishing the finished surface of the workpiece while removing a affected layer formed by the finishing cutting edge.
  • the superfinishing cutting edges project from the finishing cutting edge in such a direction that the depth of cut increases, and the superfinishing cutting edges each comprise a burnishing portion having a predetermined width in the feed direction of the tool (which is preferably not less than three times the feed rate during cutting), and a wiper portion extending from the finishing cutting edge to the burnishing portion.
  • a further feature of the invention is listed below in point 1.
  • Optional preferred forms of the cutting tools according to the invention are listed below in points 2-6.
  • the tool that meets the requirements (1) above or the tool that further meets the requirements of at least one of items (2) to (6) above is preferably used such that the depth of cut d1 of the finishing cutting edge is greater than the depth of cut d2 of the superfinishing cutting edges, and the feed rate f (mm/rev) satisfies the relations 2 ⁇ L (width of the burnishing portions of the superfinishing cutting edges: mm)/f ⁇ 8 and 0.08 ⁇ f ⁇ 0.3.
  • the cutting tool according to the present invention has superfinishing cutting edges which have both the cutting function and burnishing function.
  • the superfinishing cutting edges remove a affected layer formed by the finishing cutting edge, and simultaneously burnish the surface of the workpiece, thereby applying compressive residual stress to the finished surface.
  • the superfinishing cutting edges are cut into the workpiece until their depth of cut exceeds that of the finishing cutting edge to remove a affected layer.
  • the superfinishing cutting edges have burnishing portions extending in the feed direction of the tool and having a large width.
  • feed marks formed on the finished surface by the superfinishing cutting edges are small compared to the tool of Patent document 1. This makes it possible to improve the machining efficiency by increasing the depth of cut of the superfinishing cutting edges and the feed rate of the tool, or to suppress the formation of a affected layer by reducing the load on (i.e. depth of cut of) the finishing cutting edge.
  • the machined surface has improved surface roughness with a affected layer sufficiently removed and compressive residual stress applied thereto.
  • the machined surface can thus be finished to a high quality.
  • the present invention is applicable to a cutting tool for machining aluminum and aluminum alloy (in which case the hard members involved in cutting are preferably made of sintered diamond). But advantages of the invention are especially marked for machining hardened steel.
  • the depth of cut by the superfinishing cutting edges will be not more than 0.005 mm under the influence of the elastic deformation of the workpiece.
  • compressive residual stress can be applied during burnishing, if the thickness of affected layer formed by the finishing cutting edge exceeds 0.005 mm, the superfinishing cutting edges cannot sufficiently remove such a affected layer.
  • the amount of projection B of the superfinishing cutting edges is greater than 0.1 mm, heat generation during cutting with the superfinishing cutting edges will increase to an unignorable level.
  • This increases the possibility of a affected layer being formed by the superfinishing cutting edges.
  • Such a affected layer tends to reduce the effect of burnishing, thus making it difficult to apply sufficient compressive residual stress.
  • the superfinishing cutting edges tend to deeply cut into the workpiece.
  • the superfinishing cutting edges can hardly perform burnishing. This further reduces compressive stress applied. This in turn makes it difficult to increase the fatigue strength of the machined surface.
  • the amount of projection B of the superfinishing cutting edges is preferably set within a range of 0.02 mm ⁇ B ⁇ 0.07 mm. Within this range, it is possible to remove any affected layer formed by the finishing cutting edge, which is high in machining efficiency, with the superfinishing cutting edges while preventing excessive heat generation. Burnishing can also be reliably performed.
  • the width L of the burnishing portions of the superfinishing cutting edges is preferably not less than three times the typical tool feed rate per revolution (0.05 to 0.2 mm) because with this arrangement, it is possible to apply higher compressive force to the finished surface by pressing and flattening feed marks formed on the finished surface when the shape of the finishing cutting edge is transferred onto the finished surface.
  • the width L is within the range 0.2 mm ⁇ L ⁇ 1.0 mm.
  • the burnishing portions which are curved so as to be convex outwardly of the tool, each include an arcuate cutting edge having a radius of curvature of not less than 2 mm. With this arrangement, it is possible to press and flatten feed marks formed by the finishing cutting edge at least twice.
  • the chamfer width W2 of the superfinishing cutting edges may be smaller than the chamfer width W1 of the finishing cutting edge.
  • the chamfer width W2 of the superfinishing cutting edges is not more than 0.04 mm, it is possible to suppress heat generation at the portion of the workpiece where it is machined by the superfinishing cutting edges, thereby preventing a affected layer from being formed by the superfinishing cutting edges.
  • finishing cutting edge at the corner By providing the finishing cutting edge at the corner and providing two superfinishing cutting edges on the right and left sides of the finishing cutting edge, it is possible to selectively use one of the superfinishing cutting edges.
  • the finishing cutting edge may have steps in the direction in which the tool is cut into a workpiece, whereby the steps individually cut different portions of the workpiece.
  • the burnishing portion of each of the superfinishing cutting edges may have steps in the direction in which the tool is cut into a workpiece, whereby a finished surface of the workpiece is cut first by one of the steps of which the amount of projection B is the smallest, and then by another of the steps of which the amount of projection B is the second smallest.
  • the hard members forming the portions involved in cutting are preferably made of the material described in item (6) above, because this material is durable.
  • the workpiece is cut with the depth of cut d1 of the finishing cutting edge set to be greater than the depth of cut d2 of the superfinishing cutting edges, and the feed rate f (mm/rev) set so as to satisfy the relations 2 ⁇ L (width of the burnishing portions of the superfinishing cutting edges: mm)/f ⁇ 8 and 0.08 ⁇ f ⁇ 0.3.
  • feed marks Rf formed by the finishing cutting edges will be 2.4 ⁇ m ⁇ Rf ⁇ 4.8 ⁇ m
  • feed marks Rsf formed by the superfinishing cutting edges see Fig. 14
  • the theoretical surface roughness will improve to 0.8 ⁇ m or less.
  • a high-quality finished surface is obtained with a affected layer removed and high compressive residual stress applied thereto.
  • FIG. 1 shows a diamond-shaped, negative indexable insert according to the present invention.
  • This insert 1 comprises a substrate 2 made of cemented carbide and formed with a seat 3 in each acute-angled arcuate corner (nose) having a corner angle ⁇ of 80°, and cBN-based sintered members 5 each having a carbide backing 4 and brazed to one of the seats 3.
  • the cBN-based sintered members 5 comprises a cBN-based sintered body containing not less than 65% and not more than 85% of cBN powder in volume percent and having a heat conductivity of not more than 70W/m ⁇ K, and a film of a compound of at least one element selected from the group consisting of the elements of the 4a, 5a and 6a groups in the periodic table and Al, and at least one element selected from C, N and O, such as an oxide, carbide, nitride, carbonitride or carboxynitride of e.g. Ti.
  • Fig. 2 is an enlarged top plane view of one of the indexable inserts 1.
  • Its cBN-based sintered body 5 has a cutting edge which is a ridge line defined between a rake face 8 and a flank 9.
  • the cutting edge comprises a finishing cutting edge 6 and superfinishing cutting edges 7 each connecting with one end of the finishing cutting edge 6.
  • the finishing cutting edge 6 is formed at each corner of the cutting tool, defining an arcuate nose R having a radius of curvature of R1.
  • Each superfinishing cutting edge projects by an amount of B in the direction in which the tool is cut into workpieces. For the abovementioned reason, the amount of projection B satisfies the relation 0.02 mm ⁇ B ⁇ 0.07 mm.
  • the superfinishing cutting edges 7 each comprise a burnishing portion 7a extending in the feed direction of the tool, and a wiper portion 7b extending from the end of the finishing cutting edge 6 to the burnishing portion 7a.
  • the burnishing portion 7a of each superfinishing cutting edge 7 extends in a straight line.
  • the burnishing portion 7a has a width L of 0.2 mm ⁇ L ⁇ 1.0 mm, for the abovementioned reason.
  • the wiper portion 7b is not limited to an arcuate one as shown. It may be a straight cutting edge through which the finishing cutting edge 6 and the burnishing portion 7a are connected together. A recess may be formed between the finishing cutting edge 6 and the wiper portion 7b.
  • the finishing cutting edge 6 and the superfinishing cutting edges 7 may have their edges subjected to strengthening treatment by known chamfering (as shown in Figs. 3 and 4 ).
  • the chamfers 11 formed on the superfinishing cutting edges 7 have a width W2 that is smaller than the width W1 of the chamfer 10 formed on the finishing surface 6.
  • the width W2 of the chamfer 11 preferably satisfies the relation 0.005 mm ⁇ W2 ⁇ 0.04 mm.
  • the chamfers may be flat ones (which should be connected to the rake face and flank through small arcuate portions), or those formed by round honing.
  • Figs. 5 and 6 show another embodiment of the invention, which is also a cutting tool with indexable inserts.
  • Each indexable insert 1A has a rake face 8 including a negative land 12 having an inclination angle ⁇ of 20 to 35° to improve resistance to chipping of the cutting edge.
  • the insert of this embodiment is substantially identical in structure to the insert of Fig. 1 . Thus its further description is omitted.
  • Fig. 7 shows a further embodiment.
  • the indexable inserts of Figs. 1 and 5 include superfinishing cutting edges 7 on both sides of the finishing cutting edge 6 so as to be symmetrical to each other with respect to the bisector C (see Fig. 2 ) of the corner angle so that both sides of the cutting edge are usable. But as shown in Fig. 7 , one of the superfinishing cutting edges 7 may be omitted.
  • the finishing cutting edge 6 may comprise two or more stepped portions, so that the respective stepped portions (e.g. stepped portions 6. 1 and 6. 2 shown) individually perform cutting, thus protecting the cutting edge, and suppressing heat generation and the formation of a affected layer even if the entire finishing cutting edge 6 is cut deep into a workpiece.
  • the respective stepped portions e.g. stepped portions 6. 1 and 6. 2 shown
  • the superfinishing cutting edges 7 may also each comprise two or more stepped portions.
  • the respective stepped portions e.g. stepped portions 7- 1 and 7- 2 shown individually perform cutting if the entire superfinishing cutting edge 7 is cut deep into a workpiece, thus protecting the cutting edge, and suppressing heat generation and the formation of a affected layer.
  • the present invention is applicable to cutting tools other than indexable inserts.
  • Cutting tool samples No. 1 to No. 42 shown in Tables 1A and 1B were prepared and evaluated for their cutting performance.
  • Cutting tool samples No. 1 to No. 42 are formed of cBN-based sintered members of which the portions used for cutting have different shapes from each other.
  • the cBN-based sintered members of each tool were formed by mixing cBN powder with binder powder comprising TiN and Al in a ball mill made of cemented carbide, and sintering the mixture in an ultrahigh pressure apparatus under a pressure of 5 GPa at 1500°C.
  • Such cBN-based sintered members contained 60% by volume of cBN particles having an average particle diameter of 3 ⁇ m, the balance being Ti compounds primarily comprising TiN, Al compounds such as nitrides, borides or oxides of Al, and trace amounts of W and/or Co compounds.
  • any of the cutting tools used in this evaluation test comprised a substrate made of cemented carbide, and cBN-based sintered members each having a thickness of 1.8 mm, a nose angle ⁇ of 80° and a bottom length of 4 mm, including a carbide backing made of cemented carbide and brazed to one of the corners of the substrate.
  • the cBN-based sintered members are inserts each classified into CNMA120404, CNMA120408 or CNMA120412 under ISO and having a cutting edge comprising a conventional arcuate nose or wiper edge, or superfinishing cutting edges which characterize the present invention.
  • the cBN-based sintered members were brazed to the substrate using a active brazing metal comprising 72 wt% of Ag, 25 wt% of Cu and 3 wt% of Ti.
  • chamfers having a predetermined angle were formed on the respective cutting edges.
  • tools according to the invention tools No. 13 to No. 42
  • a rake face was formed at the cutting edge portion by grinding, and the finishing cutting edge and the superfinishing cutting edges were formed by wire electric discharge machining (WEDM). Thereafter, chamfers were formed on the finishing cutting edge and the superfinishing cutting edges.
  • WEDM wire electric discharge machining
  • wiper cutting edges of conventional tools With wiper cutting edges of conventional tools, the amount of projection from the arcuate nose in the direction in which the tool cuts into a workpiece is zero, so that such wiper cutting edges are never cut deeper into a workpiece than the cutting edge forming the arcuate nose is cut into the workpiece. Thus, such wiper cutting edges cannot remove any affected layer produced by the cutting edge forming the arcuate nose (affected layer disposed deeper than the troughs of feed marks).
  • wiper cutting edges of conventional tools and the burnishing portion of each superfinishing cutting edge according to the present invention had their angle ⁇ with respect to the tool feed direction determined so as to satisfy the relation 0° 20' ⁇ ⁇ ⁇ 0° 40'.
  • Each cutting tool was mounted on a holder and used for cutting with the cutting edge inclination angle ⁇ , side rake angle ⁇ n, end clearance angle ⁇ of, side clearance angle ⁇ os, end cutting edge angle ⁇ f and side cutting edge angle ⁇ s (see Fig. 12 ) set at -5°, -5°, 5°, 5°, 5° and 5°, respectively, under the following cutting conditions.
  • Tables 1A and 1B The results of the evaluation test are shown in Tables 1A and 1B. Evaluation was made for the thickness of the affected layer that remained on the finished surface after cutting, compressive residual stress of the finished surface, and the surface roughness of the finished surface. [Table 1A] Finishing cutting edge Superfinishing cutting edge Sample No.
  • Cutting tool samples No. 5 and 6 include inserts having conventional arcuate noses having radii of curvature of 0.8 mm and 1.6 mm, respectively, and each formed with a round chamfer formed by honing along the cutting edge and having a width W1 of 0.02 mm.
  • Cutting tool samples No. 7 to No. 12 include inserts each formed with a chamfer having a constant width W1 of 0.13 mm and an angle ⁇ 1 of 25° along the ridgeline, and having an arcuate nose with a radius of curvature of 0.8 mm. Each insert is further formed with wiper cutting edges having a width L.
  • Cutting tool samples No. 13 to No. 42 include inserts each having a finishing cutting edge and superfinishing cutting edges projecting from the finishing cutting edge in the direction in which the tool is cut into a workpiece, Each superfinishing cutting edge includes a burnishing portion extending in the feed direction of the tool.
  • the amount of projection B of the superfinishing cutting edges and the width L of the burnishing portions of each sample are shown in Tables 1A and 1B.
  • the border between the chamfer having a width W2 and the flank is rounded with a radius of curvature of 0.01 mm.
  • the surface roughness of the finished surface (hereinafter simply referred to as the surface roughness), the residual stress of the finished surface (hereinafter simply the residual stress), and the thickness of the affected layer on the finished surface (hereinafter simply the thickness of the affected layer) were measured for tools which did not suffer from chipping when the cutting test was 60 minutes old.
  • the surface roughness is the ten-point average roughness (Rz) as measured in the axial direction of the workpiece with a cutoff of 0.8 ⁇ m and a reference length of 4 mm.
  • the residual stress was calculated as a Young's modulus of 214 GPa and a Poisson ratio of 0.279 by measuring X-ray diffraction lines on the ⁇ -Fe (211) lattice plane by a sin2 ⁇ method (iso-inclination method) while exciting at 30 kV and 20 mA, using an X-ray diffraction device used by passing X-rays of Cu-K ⁇ through a V filter.
  • the symbol "-" indicates that there remains compressive stress.
  • the thickness of the affected layer was measured by cutting the workpiece so that its machined surface appears on the cut surface by wire electric discharge machining (WEDM), grinding the cut surface to remove any affected layer produced by WEDM, subjecting the cut surface to etching using 5% nital, and observing the structure of the affected layer that appeared on the finished surface under a metallograph.
  • WEDM wire electric discharge machining
  • Cutting tool samples No. 5 and 6 which include inserts each having a conventional arcuate nose, suffered chipping due to insufficient cutting edge strength.
  • Workpieces cut by cutting tool samples No. 1 to No. 4 developed affected layers having thicknesses in the range of 7.9 to 9.1 ⁇ m
  • workpieces cut by cutting tool samples No. 7 to No. 12 developed affected layers having thicknesses in the range of 10.5 to 16.4 ⁇ m.
  • the affected layers of workpieces cut by the cutting tool samples according to the present invention had reduced thicknesses of 0.6 to 7.6 ⁇ m, which suggests that the superfinishing surfaces served to remove affected layers.
  • samples No. 13 to 18 had superfinishing cutting edges that are identical in shape and different from each other only in the amount of projection B from the finishing cutting edge. Workpieces cut by these cutting tool samples were substantially identical in surface roughness to each other. However, the workpiece cut by sample No. 18 developed a affected layer having a thickness of 7.6 ⁇ m, which was larger than the thicknesses of affected layers formed on workpieces cut by sample No. 13 to 17. This is presumably because the depth of cut by the superfinishing cutting edges (amount of projection B of the superfinishing cutting edge) was large, i.e.
  • Samples No. 19 and 20 have the radii of curvature of the wiper portions of their superfinishing cutting edges changed to 0.4 mm and 1.2 mm, respectively. Workpieces cut by these samples were substantially equal in thickness of the affected layer, residual stress and surface roughness to a workpiece cut by sample No. 15. This indicates that the radius of curvature of the wiper portion has no substantial influence on the quality of the finished surface.
  • Samples No. 21 to 26 have the shapes and cutting edge widths (lengths) of their respective burnishing portions varied.
  • samples No. 15, 21 and 22 are compared, it is apparent that the larger the cutting edge width of the burnishing portions, the better the surface roughness of the finished surface, and also, the greater the compressive residual stress and the thickness of the affected layer tend to be. This is because the greater the cutting edge width of the burnishing portions, the larger the number of times the surface is pressed and flattened.
  • Samples No. 27 to 30 have the chamfer widths of their superfinishing cutting edges varied. The chamfers of these samples are all round chamfers. Sample The chamfers of sample No. 27 have the smallest width, i.e. 0.003 mm. Thus, sample No. 27 was low in cutting edge strength, so that its cutting edges chipped at the initial stage of cutting. There is a tendency that the larger the chamfer width of the superfinishing cutting edges, the higher the compressive residual stress and the thicker the affected layer. This is because although the larger the chamfer width, the higher the residual compressive stress because the burnishing portions become less sharp and the pressing force increases, the cutting temperature increases at the same time, so that a affected layer develops when machined by the superfinishing cutting edges. A workpiece cut by sample No. 30, of which the chamfer width was 0.05 mm, developed a affected layer having a thickness exceeding 5 ⁇ m.
  • Samples No. 33 to 42 have the chamfer angles ⁇ 2 of their superfinishing cutting edges varied within the range of 15 to 45°. Their chamfer widths W2 are also varied within the range of 0.03 to 0.05 mm. Even though the chamfer angle ⁇ 2 were varied, samples having chamfer widths W2 of 0.05 mm all developed affected layers thicker than 5 ⁇ m. These data show that the chamfer width of the superfinishing cutting edges is preferably set at 0.005 mm to 0.04 mm.
  • the chamfer of the finishing cutting edge preferably has a width greater than the chamfers of the superfinishing cutting edge.
  • Samples No. 31 and 32 have the chamfer angles of their finishing cutting edges varied. It is expected that the larger the chamfer angle of the finishing cutting edge, the larger the thickness of the affected layer formed when the workpiece is cut by the finishing cutting edge. But by suitably setting the amount of projection B of the superfinishing cutting edges and the width of the burnishing portions, the affected layer can be removed by the superfinishing cutting edges. Thus, the chamfer angle of the finishing cutting edges has little influence on the thickness of the remaining affected layer, and the residual stress and surface roughness of the finished surface.
  • Cutting tool samples No. 51 to 69 shown in Table 2 were prepared.
  • Any of the cutting tools used in EXAMPLE 2 comprised a substrate made of cemented carbide, and cBN-based sintered members each having a thickness of 1.8 mm, a nose angle ⁇ of 80° and a bottom length of 4 mm, including a carbide backing made of cemented carbide and brazed to one of the corners of the substrate.
  • the cBN-based sintered members are inserts each classified into CNMA120408, CNMA120412 or CNMA120416 under ISO and having a cutting edge comprising a finishing cutting edge forming an arcuate nose, and superfinishing cutting edges which characterize the present invention.
  • the cBN-based sintered members were of the same composition as those used in EXAMPLE 1.
  • the finishing cutting edge of any sample had a chamfer angle of 25° and a chamfer width of 0.13 mm (the border between the chamfer and the flank being rounded with a radius of curvature of 0.01 mm).
  • the chamfers of the superfinishing cutting edges were round chamfers having a radius of curvature of 0.02 mm and formed by honing.
  • Each superfinishing cutting edge has a straight burnishing portion, and projects by an amount B of 0.05 mm from the finishing cutting edge.
  • a rake face was formed at the cutting edge portion by grinding.
  • the finishing cutting edge and the superfinishing cutting edges were formed by wire electric discharge machining (WEDM).
  • WEDM wire electric discharge machining
  • the finishing cutting edge and the superfinishing cutting edges were formed by grinding with a forming grinder.
  • the finishing cutting edge and the superfinishing cutting edges were formed by laser machining. Chamfers were formed on the finishing cutting edges and superfinishing cutting edges of any of the tool samples.
  • the burnishing portions of the superfinishing cutting edges were arranged so as to form an angle ⁇ of 0° 20' ⁇ ⁇ ⁇ 0° 40' with respect to the feed direction of the tool (see Fig. 10 ).
  • a hard film coating of (Ti0.5Al0.5)N was applied to the entire surface of the tool, including the surface of the substrate by PVD.
  • Each of tool samples No. 51 to 69 were mounted on a holder and used for cutting with the cutting edge inclination angle ⁇ , side rake angle ⁇ n, end clearance angle ⁇ of, side clearance angle ⁇ os, end cutting edge angle ⁇ f and side cutting edge angle ⁇ s (see Fig. 12 ) set at -5°, -5°, 5°, 5°, 5° and 5°, respectively, under the following cutting conditions.
  • EXAMPLE 2 the thickness of a affected layer remaining on the finished surface, compressive residual stress of the finished surface and the amount of wear of the tool flank. The thickness of a affected layer and the compressive residual stress were measured in the same manner as in
  • Samples No. 51 to 57 are identical to each other and show the results when the feed conditions are changed with the width of the burnishing portions of the superfinishing cutting edges set at 0.5 mm.
  • Samples No. 65 to 67 differ from samples No. 51 to 57 in that the burnishing portions of the superfinishing cutting edges have a width of 0.2 mm and show the results when the feed conditions are changed. These results show that there is a tendency that the higher the feed rate, the lower the compressive residual stress. This is presumably because, provided tools used are of the same shape, the lower the feed rate, the lower the heat generation and thus the greater the number of times the surface is pressed by the burnishing portions of the superfinishing cutting edges, so that compressive stress is more easily applied to the surface of the workpiece.
  • the feed rate f (mm/rev) is preferably about 0.08 ⁇ f ⁇ 0.3.
  • the number of times the surface of the workpiece is pressed and flatted by the burnishing portions of the superfinishing surfaces is preferably two or more because by pressing and flattening the surface only once, no sufficient compressive residual stress can be applied to the surface of the workpiece. But if the number of times the surface is pressed and flattened is 10 or more, the amount of a affected layer formed by the superfinishing cutting edges increases to an unignorable level. Therefore, the width L of the burnishing portions and the feed rate f are preferably determined so as to satisfy the relation 2 ⁇ L (mm)/f ⁇ 8.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Cutting Tools, Boring Holders, And Turrets (AREA)
  • Finish Polishing, Edge Sharpening, And Grinding By Specific Grinding Devices (AREA)

Claims (8)

  1. Outil de coupe pour un usinage de haute qualité à haut rendement d'acier trempé dont des portions impliquées dans la coupe comprennent des éléments durs,
    ledit outil de coupe incluant une arrête de coupe de finition (6) qui est d'abord découpée en une pièce, et des arrêtes de coupe de superfinition (7) pour finir la pièce en suivant l'arrête de coupe de finition (6),
    dans lequel lesdites arrêtes de coupe de superfinition (7) se projettent depuis ladite arrête de coupe de finition (6) dans une direction telle que la profondeur de coupe augmente, la quantité de projection B des arrêtes de coupe de superfinition (7) depuis l'arrête de coupe de finition (6) étant réglée dans une plage correspondant à 0,02 mm ≤ B ≤ 0,07 mm, et comprennent chacune une portion de brunissage (7a) ayant une largeur prédéterminée selon la direction d'alimentation de l'outil, et une portion d'essuyage (7b) qui s'étend de ladite arrête de coupe de finition à ladite portion de brunissage,
    caractérisé en ce que
    lesdites portions de brunissage (7a) sont des portions droites, et la largeur L desdites portions de brunissage est réglée dans la plage correspondant à 0,2 mm ≤ L ≤ 1,0 mm,
    moyennant quoi lesdites arrêtes de coupe de superfinition (7) brunissent une surface finie de la pièce, tout en éliminant une couche affectée formée sur la surface finie par ladite arrête de coupe de finition (6).
  2. Outil de coupe selon la revendication 1, dans lequel ladite arrête de coupe de finition (6) et lesdites arrêtes de coupe de superfinition (7) présentent des chanfreins pour renforcer les arrêtes de coupe respectives, les chanfreins (11) desdites arrêtes de coupe de superfinition (7) présentant une largeur W2 inférieure à la largeur W1 du chanfrein (10) de ladite arrête de coupe de finition.
  3. Outil de coupe selon la revendication 2, dans lequel la largeur W2 desdits chanfreins (11) desdites arrêtes de coupe de superfinition est réglée dans une plage correspondant à 0,005 mm ≤ W2 ≤ 0,04 mm.
  4. Outil de coupe selon l'une quelconque des revendications 1 à 3, dans lequel ladite arrête de coupe de finition (6) est formée sur un coin, et lesdites arrêtes de coupe de superfinition (7) sont formées sur des côtés droit et gauche de ladite arrête de coupe de finition (6).
  5. Outil de coupe selon l'une quelconque des revendications 1 à 4, dans lequel ladite arrête de coupe de finition (6) présente des échelons dans la direction dans laquelle l'outil est découpé en une pièce, moyennant quoi lesdits échelons coupent individuellement différentes portions de la pièce.
  6. Outil de coupe selon l'une quelconque des revendications 1 à 5, dans lequel ladite portion de brunissage (7a) de chacune desdites arrêtes de coupe de superfinition présente des échelons dans la direction dans laquelle l'outil est découpé en une pièce, moyennant quoi une surface finie de la pièce est découpée d'abord par l'un desdits échelons dont la quantité de projection B depuis ladite arrête de coupe de finition dans la direction dans laquelle l'outil est découpé en la pièce est la plus faible, et ensuite par un autre desdits échelons dont la quantité de projection B est la deuxième quantité la plus faible.
  7. Outil de coupe selon la revendication 1, dans lequel lesdits éléments durs comprennent chacun un corps fritté à base de nitrure de bore cubique c-BN (5) dont le pourcentage volumétrique en particules de c-BN est supérieur ou égal à 65 % et inférieur ou égal à 85 % et présentant une conductivité thermique inférieure ou égale à 70 W/m·K, et un film dur constitué de carbure, de nitrure, d'oxyde, de carbonitrure ou de carboxynitrure d'au moins un élément sélectionné parmi le groupe constitué par les éléments des groupes 4a, 5a et 6a du tableau périodique ainsi que Al, et recouvrant la surface dudit corps fritté à base de c-BN.
  8. Procédé de découpe d'une pièce à l'aide de l'outil de coupe selon la revendication 1, dans lequel la pièce est découpée avec la profondeur de coupe d1 de l'arrête de coupe de finition (6) réglée pour être supérieure à la profondeur de coupe d2 des arrêtes de coupe de superfinition (7), et la vitesse d'alimentation f est réglée de manière à répondre aux relations 2 ≤ L(mm)/f(mm/rév) ≤ 8 et 0,08 ≤ f(mm/rév) ≤ 0,3, où L est la largeur des portions de brunissage des arrêtes de coupe de superfinition.
EP06730386.7A 2005-10-06 2006-03-29 Outil de coupe pour usinage haute qualité et haut rendement et procédé de coupe l'utilisant Active EP1886749B1 (fr)

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JPWO2006103982A1 (ja) * 2005-03-29 2008-09-04 住友電工ハードメタル株式会社 刃先交換型切削チップおよびその製造方法
JPWO2007013392A1 (ja) * 2005-07-29 2009-02-05 住友電工ハードメタル株式会社 刃先交換型切削チップおよびその製造方法
JP4728256B2 (ja) * 2005-10-06 2011-07-20 住友電工ハードメタル株式会社 高品位高能率加工用切削工具およびそれを用いた切削加工方法
US7802947B2 (en) * 2007-05-09 2010-09-28 Michigan Technological University Cutting tool insert having internal microduct for coolant
US20090004449A1 (en) * 2007-06-28 2009-01-01 Zhigang Ban Cutting insert with a wear-resistant coating scheme exhibiting wear indication and method of making the same

Also Published As

Publication number Publication date
EP1886749A4 (fr) 2015-04-15
US7765902B2 (en) 2010-08-03
US20080292415A1 (en) 2008-11-27
JPWO2007039944A1 (ja) 2009-04-16
JP4728256B2 (ja) 2011-07-20
CA2567077C (fr) 2013-04-09
CA2567077A1 (fr) 2007-04-06
EP1886749A1 (fr) 2008-02-13
WO2007039944A1 (fr) 2007-04-12

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